Reinforced plastic rods and methods of making same



J I URUOO HLFLHLEEUE oms'aun UUIVI y 8, 1952 R. J. FRANCIS 2,502,766

REINFORCED PLASTIC RODS AND METHODS OF MAKING SAME Filed April 10, 19483 Sheets-Sheet 1 INVEN TOR. I Pmfiarddfianas.

July 8, 1952 Filed April. 10, 1948 CROSS iili;

R. J. FRANCIS 2,602,766

REINFORCED PLASTIC RODS AND METHODS OF MAKING SAME 3 Sheets-Sheet 2 4 gN i 5 K r i E 43 f; -t :1

T 4 l6 g INVENTOR. [Ida/ail fin/161s.

LKUQD l'ififiliiillii'l DEHiibH HUUiV y 8, 1952 R. J. FRANCIS 2,602,766

REINFORCED PLASTIC RODS AND METHODS OF MAKING SAME Filed April 10, 19483 Sheets-Sheet I5 Fi .56 I

#6 20a fitmjfizzzis. L Q BY 4 Figure 3 is a similar view showing how thesmallest length of loops is made.

Figure 4 is a view showing the three lengths of loops disposed side byside in. extended condition.

Figure 5 is a view showing the lengths combined preparatory to coveringthem with a braided cover to form the final preform.

Figure 6 shows how each of the loops may be cut slightly to one side ofits lowest point, if desired.

Figure 7 shows the composite unit of Figure 5 being provided with abraided cover.

Figure 8 is a view of the completed preform.

Figure 9 is an enlarged View of one end ofthe Figure 11 is a transversesectional view taken along line ll|l of Figure 8 through the preform.

Figure 12 is a diagrammatic view showing the preform as it is pulledfrom a bath of the liquid resin into a tapered mold. I

Figure 13 is a diagrammatic view showing the preform being cured in themold which may be heated and then cooled.

Figure 14 is a side elevational'view of the completed tapered rod.

Figure 15 is a transverse sectional view taken through the smaller endof the .rod along line l5,l5 of Figure 14.

Figure 16 is a similar view through the larger end of the rod along lineIG! 6 of'Figure 14.

Figure 17 is a transverse sectional view taken along line I'I l1 ofFigure 18 through a tapered mold in which the preform may be disposedand the rod molded.

Figure 18 is a longitudinal sectional view through the mold showingresin being injected therein.

Figure 19 is a side elevational view of the rod made in the mold ofFigures 17 and 18.

Figure 20 is a transverse section through the rod taken along line 2020of Figure 19.

Figure 21 is a similar view but showing a rod of square cross-section.

Figure 22 is a view illustrating a single length of loops of yarn whichmay be used as the reinforcement in a rod of uniform cross-section.

Figure 23 shows the length of loops after it has been provided with abraided covering.

Figure 24 shows the preform of Figure 23 being pulled from a resin bathinto a mold.

Figure 25 is an enlarged view which illustrates the preform going intothe mold and shows how it is being compressed.

Figure 26 is a side elevational view, partly broken away of thecompleted rod.

' Figure 27 is a transverse sectional view taken through the rod alongline 21-21 of Figure 26.

Figure 28 is a vertical sectional view through a completed rod made byusing the preform of Figure 23 to produce a rod of uniform cross-sectionwhich is thenground to the desired taper.

Figure 29 is a vertical sectional view through a completed rod made byusing the preform of Figure 23 and forming the rod in a tapered mold.

Figure 30 is a diagrammatic view illustrating how a mandrel may beinserted within the preform as it is being provided with the braidedcovering in order to form a hollow rod.

, Figure 31 is a view of the preform with the mandrel in positiontherein.

Figure 32 is a transverse section takenalong line 32-32 of Figure 31showing the mandrel in position within the preform.

Figure 33 is a transverse sectional view through a mold with themandrel-containing preform in position therein.

Figure 34 is a transverse sectional view through the completed hollowrod.

Figure 35 is a diagrammatic view illustrating apparatus which may beused in continuously forming rods according to *rny inventiom Figure 36-is a view om" fly rod made -f-rom sections of rods produced according tomy invention.

Figure 3'7 is a similar view of a casting rod made from a single sectionof rod produced according to my invention.

With reference to the drawings, in Figures 1 to 9, inclusive, I haveillustrated how a preform of glass yarn can be formed for use in atapered rod. As shown in Figure 1, a wheel I is provided on which theyarn 2 is wound from a spool 3. A measured quantity will be wound on thewheel merely by turning-the wheel a predetermined number of revolutions.Then theresulting length of loops or skeinf of yarn willhe slippedtherefrom and will be in the form of. the largest length 4 of Figure 4.The shorter lengths 5 and 6 are similarly formed on the wheels 1 and 8,respectively, of Figures 2 arid 3. Thus, as shown in Figure 4. the threedifferent lengths .4, 5 and Bwill beprovided. Of course, any desirednumber of these lengths of loops can be provided and of any suitablelengths depending upon the length of the tapered rod to be produced.

The lengths 4, 5 and 6 are then superimposed.

' as shown in Figure 5, with one of their ends in alignment and securedtogether by a loop of wire 9. The next operation is illustrated inFigure 7. While the -unit;of Figure 5 is held by the wire 9 with thethree lengths extended, it is posilioned in a braiding machine in of anysuitable type. This machine It; carries a plurality of spools ll ofglass yarn and a covering I2 is braided on the loops throughout thelength thereof. The re-, sulting preform I 3 is illustrated in Figure 7.It will comprise the lengths 4, hand} enclosed within the braided coverl2. As shown in Figures 8, 9 and 10, th braided cover l2 will con sistof strands l4 extending helically in one direction and strands l5extending helically in the other direction braided with each other.Thus, the preform will consist of a soft mass of the elongated strandsl6, as shown in Figure9, with the strands I 4 and 15 extending helicallyaround the surface of the preform. It will be'apparent that all of thesestrands arespaced from each other. If desired and before braiding, thelengths 4, 5 and 6 of Figure 5 may each be cut slightly to one side-ofits lowest point to ,provideends' at substantially six different levelsand to there,- fore double the number of steps or shoulders onthepreform.

The tapered preform of Figure 8 is invertedand suspended by asecond wireH which is attached to the opposite end of the length 4 or tothe braidedcovering l2. The covering facilitates handling of the reinforcement. Thepreform is. immersed in a bath l8 of the resin and isjlifted therefromby the wire 11. The uncured resin will-be in' liquid formand will besufliciently thin to impregnate the yarnpf the preform but willbesuficiently viscous or tacky to adhere to the yarn and fill theinterstices of the preform, binding all the strands thereof intoa-single mass. The resulting soft viscous mass is then pulled up intothe SEARCH R00! 2 992 766 7 .8 In Figure 36, I illustrate a fly rodwhich is 10. The method of forming a reinforced plastic made of twosections 26a: and 26b." The base rod whichcomprises producing a preformof yarn section '26b-is hollow and of'the typeillustrated by forming itinto a length of loopsand then in Figure 34 extent thatit-preierably' ofheX- braiding a covering of yarn around the stretched agonal. form butmaybeof any other'desired 5 length, impregnatingthe strands of yarn withcross-section. 'The. ,tip.section Midis solid and resin and fillingthe-spaces between the strands preferably of the shown in Figure"lQQ-alwith resin, compressing the resin-carrying prefihollghit b l 1 -1bif'Figfires 14,. 28 01 form into the form of a rod, and then curingmade of a d Q 81 S w f l q j i i 11. A method according to claim 10wherein 2 or 2 This rod may be o hexa o a circ la a ngle length of loopsof yarn is used which or other suitable crosssectio'n. f Q: extendstheffull length 9f t rod and wherein It will be appare t'f q theaboyed'e cj ib the yarn s braided ;into strands extending t I have providedarei fo 'cedi -r of ghelically; n both directions around; t e said greatstrength both'inregard to 'fleiiu'rali'strjength 5 length I as well astorsional strength 'ancl witli tn e k 12, A method accordingto claim 10wherein resistance to 'd ami ibi "Peeling.. T a plurality; of differentlengths ofloops of yarn inforceinent is so incorporated within thefrodfqrme'd. and t lengths are superimposed and distributed thereintha impagO m with one of their ends alignment. before the tratdnoint loading o trod will t d braided cover is applied thereto, and then the ,bilted i DE h T P 3 cq resulting preform is impregnated with and covstructed intapermg "form to have varymg 'ered with aresin and is, cured in atapered mold.

claim is:

within a cured thermosettinglresinjlsaid reinfixibility and may have the"reinforcement '13. A method according to claim 12 wherein denser at theSmaller end 110 i it suflicient the non-aligning ends of the lengths ofloops are Strengthmethod of Producmg it is 51mph cut so, that the outendsiof each length will be and economical. The preform of reinforcementout f alignment 4 Y n is suc t a not mP strengtl} 9 the 14. The methodof forming a reinforced plasfinished article 1? t??? j 3 93 3 ticrod'which comprises forming a series of difi11g tilt} P PF S 9 in m t mt smce ferent lengthsof loops of yarn, aligning one of pm Wlth ed Q F-I'V jthe ends of said lengths and extending the Various other advajntagesb F Y lengths, braiding a covering of yarn over, the Having t d b d m venwhat I lengths while-extended,immersing the resulting i 5 preform unitina bathiof a thermosetting resin, A remforfied Plastlc h l f h 3?compressing the unit in a tapered. mold with ural and torsional, st ghmpr in the larger end of the preform in the-larger end m z b t n and teof the mold, and then subjecting the-mold to heatto cure theresina:

forcemeiltr a in the formibpehngated 15. The method of. forming areinforced plas- Bfiwds extending p m w 0 the and tie rod whichcomprises forming a length of loops strands extending 'arqu di eadjacent h n of reinforcing-yarns, placing'the length in exsurface ehest i extend-around" tended condition within a. mold, and then intherod exte i helically bothedirections je'cting thermosetting resin into'the mold, and and being braided tog ther. vfinallv heating the moldtocure the resin.

2. A reinforced, plastic rod according to claim method of forming areinforced plas- 1 wherein the l g udinal strands extend-t ;4 -tic rodwhich comprises forming a-length of full lengt of the rod: 1 loops ofyarn of substantially the length of the A reinforced as i rodaccordingto 01mm rod to be formed, immersing the length in ex- Which isof tubular formr tended form in a bath .of a thermosetting resin, 4. Areinforced plastic-rodh 0 .clalm and then pulling the'length through amold of 1 formed oiather o i e e n w c glass. suitable cross-section tocompress the unit and StrandS'a ed D i; T i ,1 f I a J cause, the yarns'to' "adhere to each other, and

5. A reinforced plastic r fie Co q claim heating the mold tocur'e theresin. 1 wherein the resinfis'a polyester r s -1 17. A" method accordingto claim '14 wherein 6. A re c Plastic d-$ 9 18: t la m the loop isfirst provided with a braided covering 1 wherein the in-is? Ph 9 i1 m:jofyarn'hefore being disposed inthe mold. n -I Q 'P i$ IQ harms 39t:QQX' 1'1" 18; -A method-according to ,claim 16 wherein 1 and si en o nrns-w the length of yarn is provided with a braided forcement embedded dcompletely e h s covering of yarn before being. immersed in the within acured thermosetting .resin, sa1dre1nbath of resin .f r m nt. arra ed ithe in m of e vfi 19.- Amethodzof forming a reinforced plastic textending 1 Q g tu na 1 i-0 I-the t an "rod which comprisescontinuously-feeding a, plustrands extending around the-rod adjacent theI rality of strands of yarn overa -roller co ated'with surfacethereof,thestrands which extend around :thermosetting-resin, combining,the'strandsinto e o ex en in h i a y nt b d e n ea-si le roup whi will dr otr c i o r.

an being ai ed-hea h n -mi b n pere bra n ho rin y r x-pn he up a andthee nt eo r o ceme to resin m n e es l n run tcontinuously throu hvarying at ifie nth ei e g ui le e wh h com e e i enfiwh hpu th therod-1.; e

8. A rod accord ng to claim 7 where the rein- 4 120. Ameth odgif formingaltapered reinforced forcing strands extend the-full length-or the rod.plastic rod-which comprises form n a preform ,9, rod a e i dihglto claim'Z'wherin the reinof elongated strands and embedding the-preiorm forcingsefigrard the. c t v.e t ee rer dime si s q il e st and are extend thefull length thereof ;Wh 1 those 1 0' a d so thatthey extend-theiullilengthof Wards the u e ii lie te m ates hfte r th e t: eeas d; 9e:i. difie {at 21. A method of forming a reinforced plastic rod whichcomprises molding a resin mass into a uniform rod with elongated strandsof reinforcement extending the full length thereof and then grinding therod to tapered form to expose the ends of some of the strands at thetapered surface.

22. A reinforced plastic rod having both fiexural and torsional strengthcomprising reinforcement embedded in and completely enclosed within acured thermosetting resin, said reinforcement being arranged in the formof elongated strands extending longitudinally of the rod and strandsextending around the rod adjacent the surface thereof, the strands whichextend around the rod extending helically in both directions and beingbraided together, the longitudinal strands being arranged in groupswhich extend for different portions of the length of the rod.

23. A reinforced plastic rod according to claim 22 which is tapered withthe larger end of the rod containing the greater number of strands.

24. A reinforced plastic rod according to claim 23 wherein thereinforcing in the smaller end of the rod is more dense than in thelarger end of the rod.

25. A reinforced plastic rod according to claim 22 which is of tubularform.

26. A reinforced plastic rod according to claim 22 wherein the strandsare of glass.

27. A reinforced plastic rod having both flexural and torsional strengthcomprising reinforcement embedded in and completely enclosed within acured thermosetting resin, said reinforcement being arranged in the formof elongated strands extending longitudinally of the rod and strandsextending around the rod adjacent the surface thereof, the strands whichextend around the rod extending helically.

28. A reinforced plastic rod according to claim 27 of tubular form.

v 29. A reinforced plastic rod according to claim 27 wherein thelongitudinal strands extend for different portions of the length of therod.

30. A reinforced plastic rod of tapered form comprising reinforcementembedded in and completely enclosed within a cured thermosetting resin,said reinforcement being arranged in the form of elongated strandsextending longitudinally of the rod, the longitudinal strands extendingfor different portions of the length of the rod and the ends of some ofthe strands being exposed at the tapered surface.

RICHARD J. FRANCIS.

REFERENCES CITED The following references are of record in the file ofthis patent:

UNITED STATES PATENTS Number Name Date 244,619 King July 19, 18811,409,148 Apple Mar. 14, 1922 1,751,911 Georgi Mar. 25, 1930 2,133,183Baird et a1 Oct. 11, 1938 2,175,204 'Lougheed Oct. 10, 1939 2,202,014Lougheed May 28, 1940 2,234,560 Keyes Mar. 11, 1941 2,262,861 Rugeley eta1 Nov. 18, 1941 2,308,825 Rawlings Jan. 19, 1943 2,311,704 Simison Feb.23, 1943 2,309,903 Hume Feb. 2, 1943 2,322,756 Wallder June 29, 19432,354,110 Ford et al July 18, 1944 2,379,881 Chamberlain July 10, 19452,392,805 Biefeld Jan. 15, 1946 2,425,293 McDermott Aug. 12, 19472,445,231 McDermott July 13, 1948 2,508,521 Lay May 23, 1950 2,571,692Dubois Oct. 16, 1951 2,573,361 Rodgers et a1 Oct. 30, 1951 FOREIGNPATENTS Number Country Date 502,409 Great'ifiritain Mar. 13, 1939627,255 Great Britain Aug. 4, 1949

1. A REINFORCED PLASTIC ROD HAVING BOTH FLEXURAL AND TORSIONAL STRENGTHCOMPRISING REINFORCEMENT EMBEDDED IN AND COMPLETELY ENCLOSED WITHIN ACURED THERMOSETTING RESIN, SAID REINFORCEMENT ARRANGED IN THE FORM OFELONGATED STRANDS EXTENDING LONGITUDINALLY OF THE ROD AND STRANDSEXTENDING AROUND THE ROD ADJACENT THE SURFACE THEREOF, THE STRANDS WHICHEXTEND AROUND THE ROD EXTENDING HELICALLY IN BOTH DIRECTIONS AND BEINGBRAIDED TOGETHER.
 10. THE METHOD OF FORMING A REINFORCED PLASTIC RODWHICH COMPRISES PRODUCING A PREFORM OF YARN BY FORMING IT INTO A LENGTHOF LOOPS AND THEN BRAIDING A COVERING OF YARN AROUND THE STRETCHEDLENGTH, IMPREGNATING THE STRANDS OF YARN WITH RESIN AND FILLING THESPACES BETWEEN THE STRANDS WITH RESIN, COMPRESSING THE RESIN-CARRYINGPREFORM INTO THE FORM OF A ROD, AND THEN CURING THE RESIN TO FORM THECOMPLETED ROD.